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US20140190546A1 - Solar module and solar module manufacturing method - Google Patents

Solar module and solar module manufacturing method Download PDF

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Publication number
US20140190546A1
US20140190546A1 US14/186,280 US201414186280A US2014190546A1 US 20140190546 A1 US20140190546 A1 US 20140190546A1 US 201414186280 A US201414186280 A US 201414186280A US 2014190546 A1 US2014190546 A1 US 2014190546A1
Authority
US
United States
Prior art keywords
solar cell
wiring
wiring member
solar
piece
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/186,280
Other languages
English (en)
Inventor
Shuji Fukumochi
Yoshiyuki Kudo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Corp
Panasonic Intellectual Property Management Co Ltd
Original Assignee
Sanyo Electric Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sanyo Electric Co Ltd filed Critical Sanyo Electric Co Ltd
Assigned to SANYO ELECTRIC CO., LTD. reassignment SANYO ELECTRIC CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUKUMOCHI, SHUJI, KUDO, YOSHIYUKI
Publication of US20140190546A1 publication Critical patent/US20140190546A1/en
Assigned to PANASONIC CORPORATION reassignment PANASONIC CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SANYO ELECTRIC CO., LTD.
Assigned to PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD. reassignment PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PANASONIC CORPORATION
Abandoned legal-status Critical Current

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Classifications

    • H01L31/188—
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F71/00—Manufacture or treatment of devices covered by this subclass
    • H10F71/137—Batch treatment of the devices
    • H10F71/1375—Apparatus for automatic interconnection of photovoltaic cells in a module
    • H01L27/1422—
    • H01L31/0504—
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/90—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers
    • H10F19/902—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells
    • H10F19/908—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells for back-contact photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/20—Electrodes
    • H10F77/206—Electrodes for devices having potential barriers
    • H10F77/211—Electrodes for devices having potential barriers for photovoltaic cells
    • H10F77/219—Arrangements for electrodes of back-contact photovoltaic cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to a solar module and to a method for manufacturing a solar module.
  • Solar modules are usually provided with a solar cell string having a plurality of solar cells connected electrically by a wiring member.
  • Patent Document 1 describes the use of damage-free solar cells in a solar cell string made possible by removing any damaged solar cell from the solar cell string and replacing the damaged solar cell with a new solar cell.
  • the solder bonding the solar cell to the wiring member is heated and melted to peel the wiring member from the solar cell.
  • Patent Document 1 Laid-Open Patent Publication No. 2011-134765
  • Patent Document 1 when the wiring member is bonded to the solar cell using a resin adhesive, it is difficult to reliably remove the resin adhesive using heat. As a result, the method described in Patent Document 1 cannot be used when wiring members and solar cells are bonded to each other using a resin adhesive.
  • the new solar cell is usually connected electrically using a wiring member having resin film and wiring arranged on the resin film (the “wiring member having resin film and wiring arranged on the resin film” is also referred to as a “printed circuit board” below).
  • the printed circuit board is sometimes connected using solder.
  • a solar cell string is created by electrically connecting a plurality of solar cells by bonding a wiring member to the solar cells using a resin adhesive.
  • the solar cell string is inspected for the presence of any defective solar cell, and the wiring members bonding a defective solar cell to the solar cells adjacent to the defective solar cell are disconnected, and the defective solar cell removed from the solar cell string when a defective solar cell has been discovered.
  • the tip portions of the wiring member pieces electrically connected to the new solar cell are electrically connected to the disconnected pieces of the wiring members connected electrically to adjacent solar cells while the wiring member pieces are interposed between the adjacent solar cells.
  • the first solar module of the present invention includes a plurality of solar cells, a wiring member, and a resin adhesive layer.
  • the wiring member electrically connects the plurality of solar cells.
  • the resin adhesive layer bonds the solar cells and the wiring member.
  • the wiring member has a first wiring member piece and a second wiring member piece.
  • the first wiring member piece is connected electrically to one solar cell of two adjacent solar cells.
  • the second wiring piece is connected electrically to the other solar cell of the two adjacent solar cells.
  • the second wiring member piece is also connected electrically to the first wiring member piece.
  • the tip portion of the second wiring member piece is interposed between the first wiring member piece and the one solar cell of the two adjacent solar cells.
  • a plurality of solar cells is prepared having a first electrode and a second electrode on one main surface.
  • a first wiring member is prepared having a first insulating film with flexible properties, and first wiring arranged on one main surface of the first insulating film.
  • a solar cell string is created having a plurality of electrically connected solar cells by bonding a solar cell to a first wiring member using a resin adhesive while the first wiring side of the first wiring member is facing the solar cell to establish an electrical connection.
  • the solar cell string is inspected for the presence of any defective solar cell, disconnecting the first wiring members bonding a defective solar cell to the solar cells adjacent to the defective solar cell, and the defective solar cell is removed from the solar cell string when a defective solar cell has been discovered.
  • a new solar cell is electrically connected to a solar cell adjacent to the defective solar cell using a new wiring member, the disconnected piece of the first wiring is bent to form a first exposed portion in the disconnected piece having first wiring exposed on the one main surface side of the solar cell, and the new wiring member is connected electrically to a section of the first wiring positioned in the first exposed portion.
  • the third method of the present invention for manufacturing a solar module is a method related to a solar module provided with a wiring member having resin film and wiring arranged on the resin film and connected electrically using solder.
  • the wiring member prepared for this manufacturing method is a wiring member having a section on which at least the resin film has not been provided.
  • the wiring and a connected portion are connected electrically by melting solder using a heater, and the solder is interposed between the connected portion and the section of the wiring member on which at least the resin film has not been provided.
  • the second solar module of the present invention includes a solar cell, a wiring member, and solder.
  • the wiring member has resin film and wiring arranged on the resin film.
  • the solder electrically connects the solar cell and the wiring member either directly or indirectly.
  • the resin film is not provided in at least some of the section of the wiring member electrically connected to the solar cell either directly or indirectly.
  • the present invention is able to provide a manufacturing method suitable for solar modules.
  • FIG. 1 is a simplified back view of a solar cell in the first embodiment.
  • FIG. 2 is a simplified side view of a solar cell string in the first embodiment.
  • FIG. 3 is a simplified plan view of section III in FIG. 2 .
  • the region in which a resin adhesive layer is provided is cross-hatched.
  • the cross-hatched region is not shown in cross-section.
  • FIG. 4 is a simplified cross-sectional view from line IV-IV in FIG. 3 .
  • FIG. 5 is a simplified back view of a wiring member in the first embodiment.
  • FIG. 6 is a simplified side view used to explain the solar module manufacturing process in the first embodiment.
  • FIG. 7 is a simplified side view used to explain the solar module manufacturing process in the first embodiment.
  • FIG. 8 is a simplified cross-sectional view used to explain the solar module manufacturing process in the first embodiment.
  • FIG. 9 is a simplified cross-sectional view of the solar module in the first embodiment.
  • FIG. 10 is a simplified side view used to explain the solar module manufacturing process in the second embodiment.
  • FIG. 11 is a simplified cross-sectional view used to explain the solar module manufacturing process in the second embodiment.
  • FIG. 12 is a simplified cross-sectional view of the solar module in the second embodiment.
  • FIG. 13 is a simplified back view of a solar cell in a first modified example of the second embodiment.
  • FIG. 14 is a simplified cross-sectional view of a portion of the solar module in a second modified example of the second embodiment.
  • FIG. 15 is a simplified plan view from arrow XV in FIG. 10 .
  • FIG. 16 is a simplified partial cross-sectional view from line XVI-XVI in FIG. 10 .
  • FIG. 17 is a simplified cross-sectional view of the solar module in the third embodiment.
  • FIG. 18 is a simplified cross-sectional view of a wiring member in a first modified example of the third embodiment.
  • FIG. 19 is a simplified plan view of a wiring member in a second modified example of the third embodiment.
  • the solar cells 20 shown in FIG. 1 are prepared.
  • the solar cells 20 are back contact solar cells.
  • the solar cells in the present invention are not limited to being back contact solar cells.
  • Each solar cell 20 has a photoelectric conversion unit 23 .
  • the photoelectric conversion unit 23 When exposed to light, the photoelectric conversion unit 23 generates carriers such as electrons and holes.
  • the photoelectric conversion unit 23 has a light-receiving surface (not shown) and a back surface 23 a .
  • the back surface 23 a of the photoelectric conversion unit 23 has both a p-type surface and an n-type surface.
  • the photoelectric conversion unit 23 may include a crystalline semiconductor substrate, and a p-type semiconductor layer and an n-type semiconductor layer provided on the same main surface of the substrate.
  • the p-type surface is composed of the p-type semiconductor layer.
  • the n-type surface is composed of the n-type semiconductor layer.
  • a substantially intrinsic i-type semiconductor layer may be interposed between the substrate and both the p-type semiconductor layer and the n-type semiconductor layer at a thickness ranging from several ⁇ to 250 ⁇ which does not substantially contribute to the generation of electricity.
  • the photoelectric conversion unit 23 may be composed of a crystalline semiconductor substrate having both a p-type dopant diffusion region and an n-type dopant diffusion region provided on one main surface.
  • the crystalline semiconductor substrate can be composed of single-crystal silicon.
  • the p-type semiconductor layer can be composed of p-type amorphous silicon.
  • the n-type semiconductor layer can be composed of n-type amorphous silicon.
  • the i-type semiconductor layer can be composed of i-type amorphous silicon.
  • a first electrode 21 and a second electrode 22 are arranged on the back surface 23 a of the photoelectric conversion unit 23 .
  • Either the first electrode 21 or the second electrode 22 is a p-side electrode, and the other electrode is the n-side electrode.
  • the p-side electrode is connected electrically to the p-type surface and collects holes.
  • the n-side electrode is connected electrically to the n-type surface and collects electrons.
  • Both the first electrode 21 and the second electrode 22 have a comb shape. More specifically, both the first electrode 21 and the second electrode 22 have a plurality of finger portions 21 a, 22 a extending in the x-direction (one direction), and a busbar portion 21 b, 22 b connected electrically to the finger portions 21 a , 22 a.
  • the finger portions 21 a and the finger portions 22 a are interdigitated in the y-direction (the other direction) which is orthogonal to the x-direction.
  • Busbar portion 21 b is arranged on the x1 side (the one side) of the finger portions 21 a in the x-direction.
  • Busbar portion 21 b is provided from one end to the other in the y-direction on the x1 end of the back surface 23 a.
  • Busbar portion 22 b is arranged on the x2 side (the other side) of the finger portions 22 a in the x-direction.
  • Busbar portion 22 b is provided from one end to the other in the y-direction on the x2 end of the back surface 23 a.
  • the prepared solar cells 20 are connected electrically. More specifically, a solar cell string 25 with a plurality of solar cells 20 connected electrically via wiring members 30 is created by using a wiring member 30 to electrically connect the first electrode 21 of a solar cell 20 to the second electrode 22 of the adjacent solar cell 20 in the x-direction.
  • Each wiring member 30 has a slender shape extending in the y-direction. More specifically, the wiring member 30 has a rectangular shape extending longitudinally in the y-direction. As shown in FIG. 3 through FIG. 5 , the wiring member 30 has an insulating substrate 31 and wiring 32 .
  • the insulating substrate 31 can be made of a resin or a ceramic.
  • the insulating substrate 31 can be, for example, a flexible resin substrate.
  • “substrate” may refer to a flexible sheet or film.
  • the wiring 32 is arranged on the surface 31 a of the insulating substrate 31 on the solar cell 20 side.
  • the wiring 32 is arranged on the solar cell 20 side, and the insulating substrate 31 is arranged on the side opposite the solar cell 20 .
  • the wiring 32 has conductive properties and is used to electrically connect adjacent solar cells 20 in the x-direction.
  • the wiring 32 has a wiring main body 32 a and a plurality of first and second linear portions 32 b, 32 c.
  • the wiring main body 32 a has a slender shape. More specifically, the wiring main body 32 a is rectangular.
  • the central portion of the wiring main body 32 a extending in the x-direction of the insulating substrate 31 extends from one end of the insulating substrate 31 in the y-direction, the y-direction being the direction in which the insulating substrate 31 extends.
  • Each of the first linear portions 32 b extends from the wiring main body 32 a in the x-direction towards the x1 end.
  • the first linear portions 32 b are interdigitated in the y-direction.
  • Each of the first linear portions 32 b is connected electrically to the wiring main body 32 a.
  • the first linear portion 32 b is arranged on the first electrode 21 .
  • the first linear portion 32 b is connected electrically to the first electrode 21 . More specifically, the first linear portion 32 b is arranged on the finger portions 21 a of the first electrode 21 , and connected directly to the finger portions 21 a electrically. In the present embodiment, the first linear portion 21 b is not connected directly to the busbar portion 21 b electrically. However, in the present invention, the first linear portion may be connected electrically to the busbar portion directly and not via the finger portions.
  • Each of the second linear portions 32 c extends in the x-direction towards the x2 end from the wiring main body 32 a.
  • the second linear portions 32 c are interdigitated in the y-direction.
  • Each of the second linear portions 32 c is connected electrically to the wiring main body 32 a.
  • the second linear portions 32 c are arranged on the second electrode 22 .
  • the second linear portions 32 c are connected electrically to the second electrode 22 . More specifically, the second linear portions 32 c are arranged on the finger portions 22 a of the second electrode 22 , and electrically connected to the finger portions 22 a directly. In the present embodiment, the second linear portions 32 c are not connected directly to the busbar portion 22 b electrically. However, in the present invention, the second linear portions may be connected electrically to the busbar portion directly and not via the finger portions.
  • the wiring member 30 and the solar cells 20 are bonded using a resin adhesive.
  • the wiring member 30 and the solar cells 20 are bonded using a resin adhesive layer 40 containing a cured resin adhesive.
  • the resin adhesive layer 40 may contain a conductive material in addition to the cured resin adhesive.
  • the wiring 32 of the wiring member 30 may be connected electrically to the first electrode 21 and the second electrode 22 via direct contact, or may be connected electrically via the conductive material instead of via direct contact.
  • the wiring 32 is preferably connected electrically to the first electrode 21 and the second electrode 22 via direct contact.
  • a defective solar cell means any solar cell that is scratched or damaged, or any solar cell whose semiconductor junctions have not been formed properly and which does not generate electricity when exposed to light.
  • defective solar cells include physically defective solar cells and electrically defective solar cells.
  • Defective solar cells can be detected by performing a visual inspection using a microscope, an inspection using the photoluminescence (PL) method in which fluorescent light is detected when light is incident on the light-receiving surface, and an inspection using the electroluminescence (EL) method in which fluorescent light is detected when voltage is applied.
  • PL photoluminescence
  • EL electroluminescence
  • solar cell 20 a because solar cell 20 a was found to be defective in the inspection process, solar cell 20 a has to be replaced in the replacement process. When no defective solar cells are found in the inspection process, the replacement process is not performed.
  • the solar cell 20 a is first removed from the solar cell string 25 . More specifically, the solar cell 20 a found to be defective and the wiring members 30 a, 30 b bonded to the solar cells 20 b, 20 c adjacent to the solar cell 20 a are cut. More specifically, the unbonded portion of wiring member 30 a not bonded to the solar cells 20 is cut along cut line L 1 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 b. Also, the unbonded portion of wiring member 30 b not bonded to the solar cells 20 is cut along cut line L 2 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 c. Afterwards, solar cell 20 a is removed from the solar cell string 25 . The disconnected piece 30 a 1 of wiring member 30 a, and the disconnected piece 30 b 1 of wiring member 30 b shown in FIG. 6 are bonded, respectively, to solar cell 20 b and solar cell 20 c.
  • the disconnected piece 30 a 1 of wiring member 30 a is cut so as to extend to the outside of the solar cell 20 b, and the disconnected piece 30 b 1 of wiring member 30 b is cut so as to extend to the outside of solar cell 20 c.
  • the cut lines L 1 , L 2 are preferably closer to solar cell 20 a than to solar cell 20 b and solar cell 20 c.
  • the new solar cell 20 d connected electrically to the first wiring member pieces 34 a, 34 b is prepared.
  • the new solar cell is a solar cell that was not included in the solar cell string inspected in the inspection process, and may be an unused solar cell or a solar cell that has been used before but is free of defects.
  • the first wiring member piece 34 a has substantially the same configuration as the disconnected piece of the wiring member 30 a bonded to the defective solar cell 20 a. As shown in FIG. 7 , the first wiring member piece 34 a has an insulating substrate 38 a, and wiring 38 b connected electrically to the first electrode 21 and the second electrode 22 . The first wiring member piece 34 a is bonded to the solar cell 20 d via a resin adhesive layer 41 .
  • the first wiring member piece 34 b has substantially the same configuration as the disconnected piece of the wiring member 30 b bonded to the defective solar cell 20 a.
  • the first wiring member piece 34 b has an insulating substrate 38 a, and wiring 38 b connected electrically to the first electrode 21 and the second electrode 22 .
  • the first wiring member piece 34 b is bonded to the solar cell 20 c via a resin adhesive layer 41 .
  • disconnected piece 30 a 1 and first wiring member piece 34 a are connected electrically using the second wiring member piece 35 a.
  • disconnected piece 30 b 1 and first wiring member piece 34 b are connected electrically using the second wiring member piece 35 b .
  • second wiring member piece 35 a has an insulating substrate 37 a and wiring 36 a arranged on the insulating substrate 37 a
  • second wiring member piece 35 b has an insulating substrate 37 b and wiring 36 b arranged on the insulating substrate 37 b.
  • Wiring 36 a and wiring 38 b are connected electrically to wiring 36 b and wiring 32 , respectively.
  • the method used to electrically connect wiring 36 a and wiring 38 b to wiring 36 b and wiring 32 can involve bonding them via direct contact using a resin adhesive, or joining them using solder.
  • the second wiring member 35 a is arranged so the x1 end of the second wiring member 35 a is positioned between solar cell 20 b and disconnected piece 30 a 1 , and the x2 end of the second wiring member 35 a is positioned between solar cell 20 d and wiring member piece 34 b. Also, the second wiring member 35 b is arranged so the x1 end of the second wiring member 35 b is positioned between solar cell 20 d and wiring member piece 34 a , and the x2 end of the second wiring member 35 b is positioned between solar cell 20 c and disconnected piece 30 b 1 .
  • wiring member piece 33 a and disconnected piece 30 a 1 are connected electrically with the x1 end of the wiring member piece 33 a composed of second wiring member piece 35 a and first wiring member piece 34 a interposed between solar cell 20 b and disconnected piece 30 a 1 .
  • wiring member piece 33 b and disconnected piece 30 b 1 are connected electrically with the x2 end of the wiring member piece 33 b composed of second wiring member piece 35 b and first wiring member piece 34 b interposed between solar cell 20 c and disconnected piece 30 b 1 .
  • the solar cell string 25 a is sealed between first and second protecting members 11 , 12 using a bonding layer 13 . More specifically, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on the second protecting member 11 . The solar cell string 25 a is placed on top of this resin sheet, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on top of this, and the first protecting member 12 is placed on top of this. These can then be laminated in a reduced-pressure atmosphere to complete the solar module 1 .
  • the solar cell module 1 manufactured in this way has a solar cell string 25 a bonded in a bonding layer 13 between a first protecting member 11 and a second protecting member 12 .
  • the solar cell string 25 a has a plurality of solar cells 20 .
  • the solar cells 20 are connected electrically via wiring members 30 , 30 A.
  • the wiring members 30 , 30 A and the solar cells 20 are bonded via resin adhesive layers 40 , 41 containing cured resin adhesive.
  • Wiring member 30 A is connected electrically to a first electrode 21 or a second electrode 22 of a solar cell 20 , and is composed of the disconnected pieces 30 a 1 , 30 b 1 connected electrically to the wiring member pieces 33 a, 33 b.
  • the end of wiring member piece 33 a is interposed between solar cell 20 b and disconnected piece 30 a 1 .
  • the end of wiring member piece 33 b is interposed between solar cell 20 c and disconnected piece 30 b 1 .
  • Wiring member piece 33 a is composed of first wiring member piece 34 a and second wiring member piece 35 a.
  • Wiring member piece 33 b is composed of first wiring member 34 b and second wiring member 35 b.
  • One end of the second wiring member piece 35 a is interposed between solar cell 20 b and disconnected piece 30 a 1 , and the other end is interposed between solar cell 20 d and the first wiring member piece 34 a.
  • One end of the second wiring member piece 35 b is interposed between the solar cell 20 c and disconnected piece 30 b 1 , and the other end is interposed between solar cell 20 d and the first wiring member piece 34 b.
  • the wiring member piece 33 a is connected electrically to disconnected piece 30 a 1 while the tip portion of the wiring member piece 33 a is interposed between solar cell 20 b and disconnected piece 30 a 1 connected electrically to solar cell 20 b.
  • the wiring member piece 33 b is connected electrically to disconnected piece 30 b 1 while the tip portion of the wiring member piece 33 b is interposed between solar cell 20 c and disconnected piece 30 b 1 connected electrically to solar cell 20 c .
  • wiring member piece 33 a and disconnected member 30 a 1 are bonded without increasing the distance between solar cell 20 b and solar cell 20 d in the x-direction.
  • wiring member piece 33 b and disconnected member 30 b 1 are bonded without increasing the distance between solar cell 20 c and solar cell 20 d in the x-direction. As a result, the length of the electrically connected portion can be increased.
  • wiring member 30 a is disconnected so that disconnected piece 30 a 1 extends to the outside of solar cell 20 b.
  • wiring member 30 b is disconnected so that disconnected piece 30 b 1 extends to the outside of solar cell 20 c.
  • the length of the disconnected pieces 30 a 1 , 30 b 1 can be increased. This can make the electrical connection between wiring member piece 33 a and disconnected piece 30 a 1 , and between wiring member piece 33 b and disconnected piece 30 b 1 more reliable, and can increase the bonding strength. In this way, a solar module 1 with even better reliability can be manufactured.
  • wiring member piece 33 a is composed of first wiring member piece 34 a and second wiring member piece 35 a.
  • wiring member piece 33 b is composed of first wiring member piece 34 b and second wiring member piece 35 b.
  • the end portion of second wiring member piece 35 a is interposed between first wiring member piece 34 a and solar cell 20 d, and the end of second wiring member piece 35 b is interposed between first wiring member piece 34 b and solar cell 20 d.
  • first wiring member piece 34 b and the second wiring member piece 35 b can be bonded without increasing the distance between solar cell 20 c and solar cell 20 d in the x-direction, and the length of the electrically connected portion can be increased. In this way, the electrical connection between the first wiring member piece 34 a and the second wiring member piece 35 a, and between first wiring member piece 34 b and the second wiring member piece 35 b is more reliable, and the bonding strength can be increased.
  • the second wiring member piece 35 a has wiring 36 a and an insulating substrate 37 a provided between solar cell 20 b and solar cell 20 d.
  • the second wiring member piece 35 b has wiring 36 b and an insulating substrate 37 b provided between solar cell 20 c and solar cell 20 d . This can prevent short circuits between the solar cells 20 b to 20 d due to the wiring 36 a, 36 b.
  • Each solar cell 20 is a back contact solar cell having a first electrode 21 and a second electrode 22 on the back surface 23 a.
  • the operations in which disconnected piece 30 a 1 is bonded to second wiring member piece 35 a and disconnected piece 30 b 1 is bonded to second wiring member piece 35 b, and the operations in which first wiring member piece 34 a is bonded to second wiring member piece 35 a and first wiring member piece 34 b is bonded to second wiring member piece 35 b can all be performed on the back surface side.
  • the solar cell string 25 does not have to be turned over during the exchange process, which makes the exchange process easier to perform.
  • wiring member piece 33 a is composed of a first wiring member piece 34 a and a second wiring member piece 35 a
  • wiring member piece 33 b is composed of a first wiring member piece 34 b and a second wiring member piece 35 b .
  • the present invention is not restricted to this configuration.
  • the wiring member pieces may be integrated.
  • the solar cells in the present invention do not have to be back contact solar cells.
  • the solar cells may have a photoelectric conversion unit with a p-type surface on one main surface and an n-type surface on the other main surface.
  • FIG. 1 through FIG. 5 are referenced in the same manner as the first embodiment.
  • FIG. 1 , FIG. 3 , FIG. 4 and FIG. 10 are referenced in the same manner as the first and second embodiments.
  • the following is an explanation of an example of a manufacturing method for the solar module 1 shown in FIG. 12 .
  • the solar cells 20 shown in FIG. 1 are prepared.
  • the solar cells 20 are back contact solar cells.
  • a plurality of solar cells 20 and at least one wiring member 30 are prepared.
  • the wiring member 30 has a slender shape which extends in the y-direction. More specifically, the wiring member 30 has a rectangular shape and extends in the y-direction longitudinally.
  • the wiring member 30 has a film-like insulating substrate 31 and wiring 32 .
  • the insulating substrate 31 has flexible properties. As a result, the insulating substrate 31 can bend.
  • the insulating substrate 31 can be made of resin or a ceramic.
  • the wiring 32 is arranged on the main surface 31 a of the insulating substrate 31 on the side with the solar cells 20 .
  • the wiring member 30 has long as it has an insulating substrate 31 and wiring 32 .
  • the wiring 32 has a wiring main body 32 a and a plurality of first and second linear portions 32 b, 32 c.
  • the wiring main body 32 a has a slender shape. More specifically, the wiring main body 32 a has a rectangular shape.
  • the wiring main body 32 a has a central portion on the insulating substrate 31 in the x-direction which extends from one y-axis end of the insulating substrate 31 to the other in the y-direction, or in the direction in which the insulating substrate 31 extends.
  • Each of the first linear portions 32 b extends from the wiring main body 32 a to the x1 end in the x-direction.
  • the first linear portions 32 b are interdigitated in the y-direction.
  • Each of the first linear portions 32 b is connected electrically to the wiring main body 32 a.
  • Each of the second linear portions 32 c extends from the wiring main body 32 a to the x2 end in the x-direction.
  • the second linear portions 32 c are interdigitated in the y-direction.
  • Each of the second linear portions 32 c is connected electrically to the wiring main body 32 a.
  • a plurality of prepared solar cells 20 are connected electrically using a wiring member 30 . More specifically, a solar cell string 25 in which a plurality of solar cells 20 have been connected electrically via a wiring member 30 is created by using a wiring member 30 to electrically connect the first electrode 21 of one of two adjacent solar cells 20 in the x-direction to a second electrode 22 of another of two adjacent solar cells 20 .
  • the solar cells 20 and the wiring members 30 are bonded via a resin adhesive layer 40 containing a cured resin adhesive.
  • the resin adhesive layer 40 may contain a cured resin adhesive, or may contain a conductive material in addition to the cured resin adhesive.
  • the wiring 32 of the wiring member 30 may be connected electrically to the first electrode 21 and the second electrode 22 via direct contact, or may be connected electrically via the conductive material instead of via direct contact.
  • the wiring member 32 is preferably connected electrically to the first electrode 21 and the second electrode 22 via direct contact.
  • the first linear portions 32 b are positioned above the first finger portions 21 a of one solar cell 20 , and the wiring member 30 is bonded using a resin adhesive to a region of the one solar cell 20 excluding the region in which the x2 end of the first electrode 21 is arranged in the x-direction (including at least the first busbar portion 21 b ). In this way, the first linear portions 32 b of the wiring 32 of the wiring member 30 are connected electrically to the first finger portions 21 a of the one solar cell 20 .
  • the second linear portions 32 c are positioned above the second finger portions 22 a of the other solar cell 20 , and the wiring member 30 is bonded using a resin adhesive to a region of the other solar cell 20 excluding the region in which the x1 end of the second electrode 22 is arranged in the x-direction (including at least the second busbar portion 22 b ). In this way, the second linear portions 32 c of the wiring 32 of the wiring member 30 are connected electrically to the second finger portions 22 a of the other solar cell 20 .
  • a defective solar cell means any solar cell that is scratched or damaged, or any solar cell whose semiconductor junctions have not been formed properly and which does not generate electricity when exposed to light.
  • defective solar cells include physically defective solar cells and electrically defective solar cells.
  • Defective solar cells can be detected by performing a visual inspection using a microscope, an inspection using the photoluminescence (PL) method in which fluorescent light is detected when light is incident on the light-receiving surface, and an inspection using the electroluminescence (EL) method in which fluorescent light is detected when voltage is applied.
  • PL photoluminescence
  • EL electroluminescence
  • solar cell 20 a because solar cell 20 a was found to be defective in the inspection process, solar cell 20 a has to be replaced. When no defective solar cells are found in the inspection process, the replacement process is not performed.
  • solar cell 20 a When solar cell 20 a is replaced, solar cell 20 a is first removed from the solar cell string 25 . More specifically, the solar cell 20 a found to be defective is severed from the wiring members 30 a, 30 b bonded to the solar cells 20 b, 20 c adjacent to the solar cell 20 a (cutting process).
  • the unbonded portion of wiring member 30 a not bonded to the solar cells 20 is cut along cut line L 1 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 b.
  • the unbonded portion of wiring member 30 b not bonded to the solar cells 20 is cut along cut line L 2 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 c.
  • solar cell 20 a is removed from the solar cell string 25 .
  • the disconnected piece 30 a 1 of wiring member 30 a, and the disconnected piece 30 b 1 of wiring member 30 b remain bonded, respectively, to solar cell 20 b and solar cell 20 c via the resin adhesive layer 40 .
  • the disconnected pieces 30 a 1 , 30 b 1 are preferably longer in the x-direction. Therefore, the wiring members 30 a, 30 b are preferably cut near the portion bonded to the defective solar cell 20 a.
  • the new solar cell 20 d is prepared.
  • the new solar cell is a solar cell that was not included in the solar cell string inspected in the inspection process, and may be an unused solar cell or a solar cell that has been used before but is free of defects.
  • these wiring members 34 a and 34 b have a sheet-like insulating substrate 35 and wiring 36 .
  • the wiring members 34 a, 34 b may have a configuration that is substantially the same as or different from the wiring member 30 .
  • disconnected piece 30 a 1 bonded to solar cell 20 b that was adjacent to the defective solar cell 20 a and disconnected piece 30 b 1 bonded to solar cell 20 c that was adjacent to the defective solar cell are bent.
  • an exposed section 37 is formed in each disconnected piece 30 a 1 , 30 b 1 in which the wiring 32 is exposed on the side opposite the solar cells 20 b, 20 c.
  • the wiring 36 of the exposed sections 37 and the wiring 36 of the new wiring members 34 a, 34 b are connected electrically.
  • An insulating sheet (not shown) may be provided as a spacer in the region of the insulating substrate 35 interposed between the bent disconnected pieces 30 a 1 , 30 b 1 .
  • the insulating sheet can be a resin sheet such as an EVA sheet.
  • the solar cell string 25 a is sealed between first and second protecting members 12 , 11 using a bonding layer 13 . More specifically, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on the second protecting member 11 . The solar cell string 25 a is placed on top of this resin sheet, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on top of this, and the first protecting member 12 is placed on top of this. These can then be laminated in a reduced-pressure atmosphere to complete the solar module 1 .
  • the solar module 1 manufactured in this manner has a solar cell string 25 a sealed inside a bonding layer 13 between the first and second protecting members 12 , 11 .
  • the solar cell string 25 a has a plurality of solar cells 20 .
  • the solar cells 20 and wiring members 30 , 34 a, 34 b are bonded via a resin adhesive layer 40 containing a cured resin adhesive.
  • the electrical connection to the wiring members 34 a, 34 b and the disconnected pieces 30 a 1 , 30 b 1 is direct via welding, or via a resin adhesive, solder or a conductive paste.
  • the disconnected pieces 30 a 1 , 30 b 1 have a bent structure.
  • the electrical connections are established using exposed sections 37 formed by bending the disconnected pieces 30 a 1 , 30 b 1 .
  • This can increase the contact area between the wiring 32 of the disconnected pieces 30 a 1 , 30 b 1 , and the wiring 36 of the new wiring members 34 a, 34 b.
  • the contact resistance between the wiring 32 of the disconnected pieces 30 a 1 , 30 b 1 , and the wiring 36 of the new wiring members 34 a, 34 b can be reduced.
  • the operation performed to establish electrical connections between wiring member 34 a and disconnected piece 30 a 1 and between wiring member 34 a and disconnected piece 30 b 1 can also be improved. This makes a solar module 1 easier to manufacture.
  • the wiring 32 , 36 may be connected electrically using an anisotropically conductive resin adhesive containing a resin and a conductive material, the wiring 32 , 36 may be connected electrically using solder or a conductive paste, or the wiring 32 , 36 may be connected electrically using welding.
  • the exposed sections 37 and the wiring members 34 a, 34 b may be bonded using a resin adhesive while the wiring 32 , 36 is in direct contact.
  • the wiring 32 , 36 may be connected electrically using solder or conductive paste, or the wiring 32 , 36 may be connected electrically using welding.
  • the contact resistance between the wiring 32 , 36 can be reduced. In this way, a solar module 1 with better photoelectric conversion efficiency can be manufactured. Also, compared to a situation in which the wiring 32 , 36 is connected electrically using an anisotropically conductive resin adhesive, pressure does not have to be applied to the wiring members 34 a, 34 b and to the disconnected pieces 30 a 1 , 30 b 1 when the wiring 32 , 36 is electrically connected. The operation performed to establish electrical connections between wiring member 34 a and disconnected piece 30 a 1 and between wiring member 34 a and disconnected piece 30 a 1 can also be improved. This makes a solar module 1 easier to manufacture.
  • each of the first electrodes 21 and second electrodes 22 has a busbar portion 21 b, 22 b.
  • first and second electrodes are on one main surface.
  • each of the first electrodes 21 and second electrodes 22 can be busbarless electrodes composed of finger portions 21 a , 22 a.
  • the solar cells 20 b, 20 c are bonded to the new solar cell 20 d using new wiring members connected electrically to the new solar cell 20 d, and may be configured to include a wiring member 34 c having a bent structure substantially the same as that of disconnected piece 30 a 1 and a new wiring member 34 a connected electrically to wiring member 34 c and disconnected piece 30 a 1 .
  • the structure connecting solar cell 20 b and solar cell 20 d can be symmetrical from left to right.
  • solar cell 20 b and solar cell 20 d can be aligned in the z-direction so as to make a stepped structure less likely in the wiring member. This improves the reliability of the connection.
  • a metal plate or metal foil without insulating film may be provided instead of wiring member 34 a.
  • a metal object without insulating film and without a bent structure may also be used instead of wiring member 34 c.
  • the thickness of the metal object is preferably substantially the same as the thickness of the disconnected piece 30 a 1 having a bent structure.
  • the following is an explanation of an example of a manufacturing method for the solar module 1 shown in FIG. 17 .
  • solar cells 20 shown in FIG. 1 and the wiring member 30 shown in FIG. 3 and FIG. 4 are prepared. There are no particular restrictions on the type of solar cell 20 used.
  • the solar cells 20 may be solar cells using a crystalline semiconductor substrate, or thin-film solar cells.
  • the wiring member 30 is used to electrically connect the solar cells 20 .
  • the wiring members 30 may be composed of metal foil.
  • the wiring member is a printed circuit board having an insulating substrate 31 of resin film and wiring 32 arranged on the insulating substrate 31 .
  • the insulating substrate 31 is preferably flexible.
  • a solar cell string 25 having plurality of solar cells 20 connected electrically by wiring members 30 is created by electrically connecting the prepared solar cells 20 using wiring members 30 .
  • the solar cells 20 and wiring members 30 are secured using a resin adhesive. Therefore, as shown in FIG. 4 , the solar cells 20 and the wiring members 30 are bonded via a resin adhesive layer 40 containing a cured resin adhesive.
  • the resin adhesive layer 40 may include a conductive material and be anisotropically conductive.
  • a defective solar cell means any solar cell that is scratched or damaged, or any solar cell whose semiconductor junctions have not been formed properly and which does not generate electricity when exposed to light.
  • defective solar cells include physically defective solar cells and electrically defective solar cells.
  • Defective solar cells can be detected by performing a visual inspection using a microscope, an inspection using the photoluminescence (PL) method in which fluorescent light is detected when light is incident on the light-receiving surface, and an inspection using the electroluminescence (EL) method in which fluorescent light is detected when voltage is applied.
  • PL photoluminescence
  • EL electroluminescence
  • solar cell 20 a because solar cell 20 a was found to be defective in the inspection process, solar cell 20 a has to be replaced in the replacement process. When no defective solar cells are found in the inspection process, the replacement process is not performed.
  • the solar cell 20 a When the solar cell 20 a is replaced, the solar cell 20 a is first removed from the solar cell string 25 . More specifically, the solar cell 20 a found to be defective and the wiring members 30 a, 30 b bonded to the solar cells 20 b, 20 c adjacent to the solar cell 20 a are cut along the cut lines L 1 , L 2 (disconnection process).
  • the unbonded portion of wiring member 30 a not bonded to the solar cells 20 is cut along cut line L 1 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 b.
  • the unbonded portion of wiring member 30 b not bonded to the solar cells 20 is cut along cut line L 2 between the portion bonded to solar cell 20 a and the portion bonded to solar cell 20 c.
  • solar cell 20 a is removed from the solar cell string 25 .
  • the disconnected piece 30 a 1 of wiring member 30 a, and the disconnected piece 30 b 1 of wiring member 30 b are bonded, respectively, to solar cell 20 b and solar cell 20 c.
  • the disconnected pieces 30 a 1 , 30 b 1 are preferably longer in the x-direction. Therefore, the wiring members 30 a, 30 b are cut at least between solar cell 20 a and solar cell 20 b or solar cell 20 c, preferably near the portion bonded to the defective solar cell 20 a.
  • the new solar cell is a solar cell that was not included in the solar cell string inspected in the inspection process, and may be an unused solar cell or a solar cell that has been used before but is free of defects.
  • the new solar cell 20 d is connected to solar cells 20 b, 20 c using the new wiring members 34 a, 34 b. In this way, a new solar cell string 25 a is created.
  • wiring members 34 a and 34 b have an insulating substrate 35 of resin film, and wiring 36 arranged on the insulating substrate 35 .
  • the wiring members 34 a, 34 b may have a structure substantially the same as or different from wiring member 30 .
  • an electrical connection is established by joining, using solder, the disconnected piece 30 a 1 bonded to the solar cell 20 b that was adjacent to the defective solar cell 20 a, the wiring 32 of the disconnected piece 30 b 1 bonded to solar cell 20 c, and the wiring 36 of the new wiring members 34 a, 34 b.
  • Wiring member 34 a and wiring member 34 b have substantially the same configuration.
  • wiring members 34 a and 34 b have sections 37 in which at least an insulating substrate 35 is not provided. More specifically, a cut-out 35 A is formed in the insulating substrate 35 . In this way, a section 37 is provided which has wiring 36 but not an insulating substrate 35 . Solder 88 is interposed between this section 37 and the disconnected pieces 30 a 1 , 30 b 1 to be connected. In this situation, the solder 88 is heated by a heater 89 such as a soldering iron, and the melted solder joins and electrically connects the wiring 36 to the disconnected pieces 30 a 1 , 30 b 1 . In the present embodiment, the heater 89 applies pressure to the surface of the section 37 in which the wiring 36 is positioned on the side opposite the solder 88 . In this way, the heat from the heater 89 is transmitted via the wiring 36 to the solder 88 .
  • a heater 89 such as a soldering iron
  • the solar cell string 25 a is sealed between first and second protecting members 12 , 11 using a bonding layer 13 . More specifically, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on the second protecting member 11 . The solar cell string 25 a is placed on top of this resin sheet, a resin sheet such as an EVA sheet constituting a portion of the bonding layer 13 is placed on top of this, and the first protecting member 12 is placed on top of this. These can then be laminated in a reduced-pressure atmosphere to complete the solar module 1 .
  • the solar cell module 1 manufactured in this way has a solar cell string 25 a bonded in a bonding layer 13 between a first protecting member 11 and a second protecting member 12 .
  • the solar cell string 25 a has a plurality of solar cells 20 .
  • the solar cells 20 are connected electrically via wiring member 30 , or wiring members 34 a, 34 b and disconnected pieces 30 a 1 , 30 b 1 .
  • the wiring members 30 , 34 a, 34 b and the solar cells 20 are bonded via resin adhesive layers 40 containing cured resin adhesive.
  • the wiring members 34 a, 34 b and the disconnected pieces 30 a 1 , 30 b 1 are connected electrically using solder 88 .
  • An insulating substrate 35 is not provided in at least some of the section 37 of the wiring members 34 a, 34 b connected electrically to the solar cells 20 either directly or indirectly.
  • solder 88 is interposed between a section 37 of the wiring members 34 a, 34 b in which the insulating substrate 35 is not provided and the disconnected pieces 30 a 1 , 30 b 1 to be connected.
  • the section 37 has wiring 36 with high thermal conductivity but not an insulating substrate 35 . Therefore, the section 37 has high thermal conductivity.
  • the heater 89 is pressed against the section 37 , the heat from the heater 89 is conducted efficiently to the solder 88 . Because the solder 88 melts well, a good electrical connection can be established with the wiring members 34 a, 34 b.
  • the thermal conductivity of the wiring 36 can be improved to establish an even better electrical connection with the wiring members 34 a, 34 b. Therefore, the wiring 36 preferably contains a metal such as Cu.
  • the present invention includes many embodiments not described herein.
  • wiring 36 was provided in a section 37 not including the insulating substrate 35 .
  • the insulating substrate 35 and the wiring 36 do not have to be provided in this section 37 .
  • the section 37 may be composed of an opening or cut-out.
  • the heater 89 is applied directly to the solder 88 . Because the solder 88 can be heated more effectively, the electrical connection to the wiring members 34 a , 34 b can be improved.
  • a cut-out 35 A is provided in the insulating substrate 35 .
  • an opening 35 B may be formed in the insulating substrate 35 instead of a cut-out 35 A, wiring member 34 a may be staggered relative to disconnected piece 30 a 1 , and wiring member 34 b may be staggered relative to disconnected piece 30 b 1 to expose the wiring 36 .
  • a wiring member having resin film and wiring on the resin film may be connected electrically to a wiring member of conductive foil using solder. Also, a wiring member having resin film and wiring on the resin film may be connected electrically to the electrodes of a solar cell using solder.

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  • Engineering & Computer Science (AREA)
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US20230327035A1 (en) * 2020-08-31 2023-10-12 Longi Solar Technology (Taizhou) Co., Ltd. Interconnection piece and solar cell assembly
US20240059431A1 (en) * 2021-10-07 2024-02-22 Maxar Space Llc Modular solar array
US12454372B2 (en) * 2021-10-07 2025-10-28 Maxar Space Llc Modular solar array
WO2025068563A1 (fr) * 2023-09-28 2025-04-03 Commissariat A L'energie Atomique Et Aux Energies Alternatives Module photovoltaïque à structure flexible d'interconnexion
FR3153692A1 (fr) * 2023-09-28 2025-04-04 Commissariat A L'energie Atomique Et Aux Energies Alternatives Module photovoltaïque à structure flexible d’interconnexion

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JP6213921B2 (ja) 2017-10-18

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